Method of seam coating flooring

ABSTRACT

The seam of a surface covering product, having an exposed surface which is the reaction product of a protective coating composition including an aminoplast and a polyol, is coated with a seam coating composition including a cyanoacrylate monomer and a plasticizer. The preferred monomer is methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate or methoxy ethyl 2-cyanoacrylate. The preferred plasticizer is dibutyl phthalate. The seam coating should have a viscosity of about 100 CPS. An accelerator may be applied to the uncured seam coating.

FIELD OF THE INVENTION

The invention relates to a method of seam coating resilient sheet flooring. In particular, the invention is directed to a method of seam coating a resilient sheet flooring having a highly crosslinked wear surface, and more specifically, a wear surface which is the reaction product of a composition comprising a polyol and aminoplast.

BACKGROUND OF THE INVENTION

A highly crosslinked wear surface formed by the reaction of a composition comprising a polyol and an aminoplast has been developed which has excellent scratch and stain resistance. However, since the surface of the highly crosslinked wear layer has only a trace amount of reactive functional groups, it has been extremely difficult to discover a composition which will adhere to the wear layer and which can be used as a seam coating.

As known in the art, when two sections of resilient sheet flooring are laid with two edges abutting, a seam is formed. Unless the seam is coated with a sealing composition, dirt tends to accumulate in the seam, and due to the slight difference in surface height between the two sections of resilient flooring at the seam, traffic will tend to snag the higher surface. A seam coating eliminates the crevice at the abutment and smooths the transition between the two elevations at the abutment.

Numerous seam coating compositions are known. Further a cyanoacrylate adhesive with dibutyl phthalate plasticizer is disclosed in European patent application Ser. No. 239,890. The invention of the European Application is an opaque cyanoacrylate adhesive or coating composition which comprises a monomeric ester of 2-cyanoacrylic acid and 5 to 50% by weight, based on the monomeric ester, of a semi-compatible plasticizer. The European application compares the opaque adhesive of the European invention with a non-opaque coating of cyanoacrylate with a fully compatible dibutyl phthalate plasticizer.

Since typical seam coatings would not adhere to the polyol/aminoplast wear layer, the surface was analyzed by the present inventors to determine if there were any functional groups present which could be used to gain adhesion. Only trace amounts of N--H, C--O, C═O and C--Cl were detected. Attempts to attack or soften the wear layer surface with solvents was also evaluated. The solvents were covered with watch glasses to retard evaporation. Of the nine solvents tested, only methylene chloride, tetrahydrofuran and methyl ethyl ketone softened and/or shriveled the surface of the wear layer within a twenty minute time period. However, if any of the above solvents were allowed to evaporate to dryness without restrictions, they had no effect on the surface of the wear layer.

Typical acrylic, nitrocellulose and vinyl lacquers utilizing these most active solvents were evaluated. The wear layer acted as a release coating and the lacquers failed to gain adhesion.

Many resinous systems including cyanoacrylates, alkyds, lacquers, epoxies, polyurethanes, and crosslinkable lattices were evaluated. The surface of the wear layer was pretreated with such agents as acids, alkali and corona discharge without improving the bonding characteristics.

One objective of the present invention is to provide a method of seam coating the surface of a wear layer comprising the reaction product of an aminoplast and a polyol.

A further object is to provide a seam coating composition which will adhere to the aminoplast/polyol wear layer and have excellent stain and scratch resistance as well as an appearance similar to the surface of the aminoplast/polyol wear surface.

These and other advantages of the present invention will become apparent from the detailed description of the preferred embodiments which follows.

SUMMARY OF THE INVENTION

It has been found that of the numerous adhesives and coating compositions for resilient floor coverings, only a coating composition comprising cyanoacrylate monomer will adhere to the surface of an aminoplast/polyol wear layer and has the desired stain and scratch resistance and appearance.

DETAILED DESCRIPTION OF THE INVENTION

U.S. Pat. No. 4,781,987, issued Nov. 1, 1988, in the names of Bolgiano et al. and U.S. application Ser. No. 945,831, filed Dec. 23, 1986 in the name of Witman disclose highly crosslinked protective coatings or wear layers comprising an aminoplast, preferably melamine, and a polyol. Both of these references are incorporated herein by reference. The compositions of the Bolgiano et al. patent and Witman application yield a protective coating for resilient flooring which has superior stain and scratch resistance. However, the surface of the wear layer has only trace amounts of N--H, C--O, C═O and C--Cl functional groups and no NH₂ or OH functional groups. Therefore, it has been difficult to discover a seam coating composition which will adhere to the aminoplast/polyol wear layer.

Attempts were made to soften the surface of the wear layer with a number of solvents. The solvents were covered with watch glasses to retard evaporation. Table 1 sets forth the substance and the results of the test.

                  TABLE 1                                                          ______________________________________                                         Solvent Surface Treatment                                                                      Time for Surface                                               Solvent         Softening and/or Shriveling                                    ______________________________________                                         Methylene Chloride                                                                              4 minutes                                                     Tetrahydrofuran 12 minutes                                                     Methyl ethyl ketone                                                                            22 minutes                                                     Methyl isobutyl ketone                                                                         7 hours, slight blistering                                     Isopropanol     7 hours, none                                                  Ethanol         7 hours, none                                                  Isopropyl acetate                                                                              7 hours, none                                                  Butyl cellosolve acetate                                                                       7 hours, none                                                  Toluol          7 hours, none                                                  ______________________________________                                    

When the above solvents are allowed to evaporate to dryness without the watch glass, they have no effect on the wear layer surface. Typical acrylic nitrocellulose and vinyl lacquers utilizing the most active solvents were evaluated by applying the lacquer to the wear layer and allowing it to air dry at room temperature. Other seam coating candidates including highly crosslinked polyurethanes were also tested. The results of these tests are set forth in Table 2.

                                      TABLE 2                                      __________________________________________________________________________     Solvent                   Solvent   Adhesion and/                              Based Lacquers Type       System    or Remarks                                 __________________________________________________________________________     Acryloid ® A21.sup.1                                                                      Methyl methacrylate                                                                       MEK.sup.2 Poor - good                                (25%)                               iodine resistance                          Acryloid A21/  Methyl methacrylate/                                                                      MEK       Poor - CS-1                                Acryloid CS-1.sup.1                                                                           tackifier            lowered gloss                              Acryloid A21/  Methyl methacrylate/                                                                      MeCl.sub.2.sup.3                                                                         Poor                                       Santicizer 160 (2.5%).sup.8                                                                   plasticizer                                                     Acryloid B67.sup.1                                                                            Isobutyl   VM&P      Good after 2                                              methacrylate                                                                              naphtha   days, poor after                                                               7 days                                     Acryloid B67   Isobutyl   MEK       Poor - easily                              (Crumbs).sup.1 methacrylate         marred                                     Acryloid B67/  Isobutyl methacrylate                                                                     MEK       Poor - easily                              Acryloid DMSS.sup.1                 marred                                     Acryloid B84.sup.1                                                                            Methyl     Toluene/  Poor - poor                                               methacrylate                                                                              Sec.      iodine resistance                                                    Butanol                                              Acryloid B48S  Methyl     Toluene   Poor - poor                                (45%).sup.1    methacrylate         iodine resis.                              Acryloid B-99.sup.1                                                                           Methyl     Toluene/  Poor - brittle                                            methacrylate                                                                              xylene    good iodine                                                                    resistance                                 Acryloid XR-34.sup.1                                                                            --         --      Poor                                       Acryloid B44.sup.1 /VAGH.sup.4 /DOP.sup.5                                                     Acrylic/PVC.sup.6 /                                                                       MeCl.sub.2 /Toluol 2/1                                                                   Poor                                       3/2/1/ (25%)   Plasticizer                                                     Nitrocellulose RS.sup.7                                                                         --         --      Poor                                       Nitrocellulose SS.sup.7                                                                          --      Ethanol   Poor                                       1/2 sec (40%)                                                                  Butvar ® 90.sup.8 (20%)                                                                   Polyvinyl butyral                                                                         n-butanol/                                                                               Poor                                                                 MIBK 1/1                                             Butvar ® 98.sup.8 (15%)                                                                   Polyvinyl butyral                                                                         Toluene/  Poor                                                                 ethanol 6/4                                          Ethyl Cellulose N7 (15%)                                                                        --       Toluol/n  Poor - alcohol                                                       butanol   redissolves                                Evlacite ® 2045.sup.9                                                                     Isobutyl   MEK       Poor                                       (15%)          methacrylate                                                    Evlacite 2041.sup.9                                                                           Isobutyl   MEK       Poor                                                      methacrylate                                                    Elvacite 2041.sup.9 /                                                                         Isobutyl   MEK/THF.sup.10 /                                                                         Poor                                       VMCH.sup.4 (11%)                                                                              methacrylate/PVC                                                                          DMF.sup.11 20/4/1                                    Elvacite 2041.sup.9 /                                                                         Isobutyl   MEK/THF/DMF                                                                              Poor                                       Firestone 6336.sup.12 (11%)                                                                   methacrylate/PVC                                                                          20/4/1                                               Carboset ® XL-44.sup.13                                                                   Alkali soluble                                                                            MEK (also NH.sub.4 OH)                                                                   Poor                                       (10%)          acrylics                                                        Carboset ® 525.sup.13                                                                     Alkali soluble                                                                            MEK       Poor                                       (10%)          acrylics                                                        VAGH.sup.4 (20%)                                                                              PVC/PVAC.sup.14 /OH.sup.15                                                                MEK/MeCl.sub.2                                                                           Poor                                                                 1/1                                                  VAGH.sup.4 (25%)                                                                              PVC/PVAC/OH                                                                               cyclohexanone                                                                            Poor                                       VYES.sup.4 (40%)                                                                              PVC/PVAC/OH                                                                               MIBK.sup.16 /toluene                                                                     Good -                                                               1/1       easily marred,                                                                 poor U.V.                                  Mirabond ®.sup.17                                                                         Polyurethane                                                                              Xylene    Poor                                       Mirabond ®.sup.17                                                                           --       Added MeCl.sub.2                                                                         Poor                                                                 (20%)                                                Securabond Adhesive.sup.17                                                                    Polyamide/Epoxy                                                                             --      Poor                                       VAGH.sup.4 /THF                                                                                 --       THF       Poor                                       Whittaker's Adhesive                                                                          Polyester    --      Poor                                       #46960.sup.18                                                                  Ciba Geigy GY-9513.sup.19 /                                                                   Epoxy/       --      Poor                                       Ciba Geigy HY-2964.sup.19                                                                     Aliphatic amine                                                 __________________________________________________________________________     High Crosslinked                Adhesion and/or                                Polyurethanes    Type           Remarks                                        __________________________________________________________________________     Thermoplastic    Polyurethane   Poor - soft, rubbery                           Desmodur W.sup.20                                                                               dicyclohexyl   Poor - soft, rubbery                           Thermoplastic    methyl(4,4')diisocyanate                                                                      fair-good iodine resis.                        Desmodur W       dicyclohexyl   Poor - hard, glossy                                             methyl(4,4')diisocyanate                                      Desmodur N-100.sup.20                                                                           hexamethylene  Poor - soft, rubbery                                            diisocyanate   easily marred                                                   oligomer/catalyst                                             Desmodur N-3390.sup.20                                                                          hexamethylene  Poor - soft, rubbery                                            diisocyanate   easily marred                                                   oligomer/catalyst                                             Desmodur N-3390.sup.20                                                                          hexamethylene  Poor - soft, rubbery                                            diisocyanate   easily marred                                                   oligomer/catalyst                                             Desmodur N-3390/TMDI.sup.21                                                                     hexamethylene  1 day good (soft)                                               diisocyanate   5 days poor (hard)                                              oligomer/TMDI/                                                                 catalyst                                                      Desmodur W3398.sup.20                                                                           hexamethylene  Poor - hard, glossy                                             diisocyanate   fair-good iodine resis.                                         oligomer/catalyst                                             __________________________________________________________________________     Other Seam Coating                Adhesion and/or                              Candidates          Type          Remarks                                      __________________________________________________________________________     Congo's Seam Coater Two part urethane                                                                            Poor - poor iodine                           "Easy Does It" SN-102.sup.22                                                                       based on an aliphatic                                                                        resistance                                                       diisocyanate                                               Del Val's Ink Vehicle.sup.23                                                                       Polyamide -   Poor - yellowed                                                  Ethanol/VMP/IPAc.sup.24                                                        60/20/20                                                   Magic Appliance Touch-Up                                                                             --          Poor                                         Paint for Tubs and                                                             Sinks (White).sup.25                                                           Mobay 0402A.sup.20  Aliphatic carboxylated                                                                       Poor - soft and                                                  urethane latex                                                                               flexible                                     Spencer Kellogg     Aliphatic carboxylated                                                                       Poor - dull film                             DV 5546             urethane latex                                             Spencer Kellogg DV5546                                                                         9   Aliphatic carboxylated                                                                       Gelled on mixing                             Resimene 717.sup.8                                                                             1   Methylated Melamine                                                                          in of PTSA                                   PTSA.sup.27 10% in water                                                                       1   Catalyst                                                   Rohm and Haas E 2184.sup.1                                                                         Acrylic latex Poor - sl. yellow                                                              (dried at 30° C.)                     CDM-WJ55        2   Epoxy         Poor                                         Maincote TL-5.sup.1                                                                            1                                                              Resimene 717.sup.8                                                                             9   Methylated melamine                                                                          Poor - water                                 PTSA (10% in water)                                                                            1   Catalyst      re-soluble after                                                               10 days                                      Helastic 6545.sup.28                                                                               Aliphatic polyurethane                                                                       Poor - very poor                             Ucarlnk XL 225E.sup.4                                                                              dispersion    iodine resistance,                                               Carbodiamide  easily marred                                Helastic X915.sup.28                                                                               Aliphatic polyurethane                                                                       Poor - poor                                  Xama 7.sup.29       dispersion    iodine resistance                                                Aziridine                                                  Rhoplex WL-91.sup.1 Acrylic latex Tg 52° C.                                                               Good - good iodine                           BCA.sup.30                        resistance, easily                                                             marred                                       DER 331/DER 721.sup.31                                                                             Bisphenol A epoxy                                                                            Poor                                         DEH 58              Amine hardener                                             Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Unsatisfactory                               Resimene U-983.sup.8 in                                                                        24  Melamine                                                   ethanol/water, 95/5                                                            PTSA (40%)      0.75                                                                               Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Unsatisfactory                               Resimene 881.sup.8                                                                             20  Melamine                                                   PTSA (40%)      0.75                                                                               Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Unsatisfactory                               Resimene 872.sup.8                                                                             20  Melamine                                                   PTSA (40%)      0.75                                                                               Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Unsatisfactory                               Resimene U-983.sup.8                                                                           3   Melamine                                                   Resimene 872.sup.8                                                                             20  Melamine                                                   PTSA (40%)      0.75                                                                               Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Unsatisfactory                               Resimene U-983.sup.8                                                                           10  Melamine                                                   Resimene 872.sup.8                                                                             10  Melamine                                                   PTSA (40%)      0.75                                                                               Catalyst                                                   Resimene 747.sup.8                                                                             20  Methylated melamine                                                                          Unsatisfactory                               RJ-100.sup.8    40  Styrene allyl alcohol                                      Toluene/ethanol (1:1)                                                                          60                                                             PTSA (40%)      0.6 Catalyst                                                   Resimene 747.sup.8                                                                             20  Methylated melamine                                                                          Unsatisfactory                               RJ-100.sup.8    40  Styrene allyl alcohol                                      Toluene/ethanol (1:1)                                                                          60                                                             PTSA (40%)      1.2 Catalyst                                                   Resimene 2060.sup.8                                                                            50  Melamine      Unsatisfactory                               Toluene/ethanol (2:1)                                                                          30                                                             PTSA (40%)      5   Catalyst                                                   Resimene 2060.sup.8                                                                            50  Melamine      Unsatisfactory                               Toluene/ethanol 30                                                             PTSA (40%)      10  Catalyst                                                   Resimene 745.sup. 8                                                                            10  Melamine      Unsatisfactory                               Styrene allyl alcohol                                                                          40                                                             Toluene/ethanol (2:1)                                                                          25                                                             PTSA (40%)      5   Catalyst                                                   Resimene 745.sup.8                                                                             10  Melamine      Unsatisfactory                               Styrene allyl alcohol                                                                          40                                                             Toluene/ethanol (2:1)                                                                          25                                                             PTSA (40%)      10  Catalyst                                                   Gelva GMS 264.sup.32                                                                               Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 269.sup.32                                                                               Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 1140.sup.32                                                                              Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 1215.sup.32                                                                              Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 1430.sup.32                                                                              Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 1753.sup.32                                                                              Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 1822U.sup.32                                                                             Polyvinyl acetate -                                                                          Unsatisfactory                                                   maleate copolymer                                          Gelva GMS 1151.sup.32 /                                                                            Polyvinyl acetate -                                                                          Unsatisfactory                               PAPI isocyanate.sup.33                                                                             maleate copolymer/catalyst                                 Mirabond.sup.17 95  Polyurethane  Poor                                         KL3-2001.sup.20 5   Bonding agent                                              Mirabond.sup.17 90  Polyurethane  Poor                                         KL3-2001.sup.20 10  Bonding agent                                              S-553.sup.17    95  Vinyl sealer  Poor                                         KL3-2001.sup.20 5   Bonding agent                                              S-553.sup.17    90  Vinyl sealer  Poor                                         KL3-2001.sup.20 10  Bonding agent                                              Gelva GMS 1151.sup.32                                                                          95  PVAC-maleate copolymer                                                                       Poor                                         KL3-2001.sup.20 5   Bonding agent                                              Gelva GMS 1430.sup.32                                                                          95  PVAC-maleate copolymer                                                                       Poor                                         KL3-2001.sup.20 5   Bonding agent                                              Epon 828.sup.35 50  Epoxy         Poor                                         Versamide 1540.sup.34                                                                          17.94                                                                              Amine hardener                                             Xylene/MIBK.sup.16, 3/1                                                                        15                                                             Epon 828.sup.35 50  Epoxy         Poor                                         Versamide 1540.sup.34                                                                          17.94                                                                              Amine hardener                                             KL3-2001.sup.20 3.4 Bonding agent                                              Xylene/MIBK, 3/1                                                                               15                                                             Butvar B-98.sup.8 (20% in                                                                      90  Polyvinyl butyral                                                                            Poor - poor                                  toluene/ethanol, 1/1)             iodine resistance                            Dyno MB-98.sup.36 (97%)                                                                        15  Melamine                                                   PTSA (40%)      0.75                                                                               Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Poor - poor                                  Dyno MB-98.sup.36 (97%)                                                                        15  Melamine      iodine resistance                            PTSA (40%)      1.5 Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Poor - poor                                  Dyno MB-98.sup.36 (97%)                                                                        15  Melamine                                                   PTSA (40%)      3.75                                                                               Catalyst                                                   Butvar B-98.sup.8 (20%)                                                                        90  Polyvinyl butyral                                                                            Poor - poor                                  Dyno MB-98.sup.36 (97%)                                                                        15  Melamine      iodine resistance                            PTSA (40%)      7.5 Catalyst                                                   Dyno MB-98.sup.36                                                                              21  Melamine      Poor - poor                                  RJ-100.sup.8 (40% in                                                                           100 Styrene allyl alcohol                                                                        iodine resistance                            toluene/ethanol, 1/1)                                                          PTSA (40%)      0.6 Catalyst                                                   Dyno MB-98.sup.36                                                                              21  Melamine      Poor - poor                                  RJ-100.sup.8 (40%)                                                                             100 Styrene allyl alcohol                                                                        iodine resistance                            PTSA (40%)      1.2 Catalyst                                                   Resimene 747.sup.8                                                                             20  Methylated melamine                                                                          Poor - poor                                  RJ-100.sup.8 (40%)                                                                             100 Styrene allyl alcohol                                                                        iodine resistance                            PTSA (40%)      7.5 Catalyst                                                   Resimene 747.sup.8                                                                             20  Methylated melamine                                                                          Poor - poor                                  RJ-100.sup.8 (40%)                                                                             100 Styrene allyl alcohol                                                                        iodine reistance                             PTSA (40%)      15  Catalyst                                                   Dyno MB-98.sup.36                                                                              20.6                                                                               Melamine      Poor - poor                                  RJ-100.sup.8 (40%)                                                                             100 Styrene allyl alcohol                                                                        iodine resistance                            PTSA (40%)      7.5 Catalyst                                                   Dyno MB-98.sup.36                                                                              20.6                                                                               Melamine      Poor - poor                                  RJ-100.sup.8 (40%)                                                                             100 Styrene allyl alcohol                                                                        iodine resistance                            PTSA (40%)      15  Catalyst                                                   Butvar B-76.sup.8 (14% in MEX)                                                                 658.5                                                                              Polyvinyl butyral                                                                            Poor - poor                                  Santicizer 8.sup.8                                                                             7.5 Plasticizer   iodine resistance                            Butvar B-76.sup.8 (14%)                                                                        658.5                                                                              Polyvinyl butyral                                                                            Poor - poor                                  Santicizer 8.sup.8                                                                             7.5 Plasticizer   iodine resistance                            KL3-2001.sup.20 5.0 Bonding agent                                              Butvar B-76.sup.8 (14%)                                                                        658.5                                                                              Polyvinyl butyral                                                                            Poor - poor                                  Santicizer 8.sup.8                                                                             7.5 Plasticizer   iodine resistance                            KL3-2001.sup.20 10.0                                                                               Bonding agent                                              Butvar B-76.sup.8 (14%)                                                                        658.5                                                                              Polvinyl butyral                                                                             Poor - poor                                  Santicizer 160.sup.8                                                                           7.5 Plasticizer   iodine resistance                            Butvar B-76.sup.8 (14%)                                                                        658.5                                                                              Polyvinyl butyral                                                                            Poor - poor                                  Santicizer 160.sup.8                                                                           7.5 Plasticizer   iodine resistance                            KL3-2001.sup.20 5.0 Bonding agent                                              Butvar B-76.sup.8 (14%)                                                                        658.5                                                                              Polyvinyl butyral                                                                            Poor - poor                                  Santicizer 160.sup.8                                                                           7.5 Plasticizer   iodine resistance                            KL3-2001.sup.20 10.0                                                                               Bonding agent                                              Aroplaz 6065x50.sup.37                                                                         170.0                                                                              alkyd resin   Poor - poor                                  Aroplaz 2477x65 23.1                                                                               alkyd resin   iodine resistance                            6% Cobalt naphthenate                                                                          0.67                                                           6% manganese naphthenate                                                                       0.33                                                           Xylene          28.0                                                           45% nonvolatile solids                                                         Aroplaz 6065x50.sup.37                                                                         100 alkyd resin   Poor - poor                                  6% Cobalt naphthenate                                                                          0.33              iodine resistance                            6% manganese naphthenate                                                                       0.17                                                           Xylene          10.61                                                          45% nonvolatile solids                                                         Aroplaz 6008x50.sup.37                                                                         170.0                                                                              alkyd resin   Poor - poor                                  Aroplaz 2477x65.sup.37                                                                         23.1                                                                               alkyd resin   iodine resistance                            6% Cobalt naphthenate                                                                          0.67                                                           6% manganese naphthenate                                                                       0.33                                                           Xylene          28.0                                                           45% nonvolatile solids                                                         Aroplaz 6008x50.sup.37                                                                         100 alkyd resin   Poor - poor                                  6% Cobalt naphthenate                                                                          0.33              iodine resistance                            6% manganese naphthenate                                                                       0.17                                                           Xylene          10.61                                                          45% nonvolatile solids                                                         Aroflint 607.sup.38                                                                            50  polyester-epoxy                                                                              Poor                                         Aroflint 404xx60.sup.38                                                                        83.33                                                                              polyester-epoxy                                            Dowanol PMA.sup.31                                                                             10                                                             69.77% nonvolatile solids                                                      Aroflint 607.sup.38                                                                            50  polyester-epoxy                                                                              Poor                                         Aroflint 252zm160.sup.38                                                                       83.33                                                                              polyester-epoxy                                            Dowanol.sup.31  10                                                             __________________________________________________________________________      .sup.1 Sold by Rohm and Haas Company                                           .sup.2 Methyl ethyl ketone                                                     .sup.3 Methylene chloride                                                      .sup.4 Sold by Union Carbide Corp.                                             .sup.5 Dioctyl phthalate                                                       .sup.6 Polyvinyl chloride                                                      .sup.7 Sold by Hercules Inc.                                                   .sup.8 Sold by Monsanto Chemical Co.                                           .sup. 9 Sold by E. I. Du Pont Le Nemours                                       .sup.10 Tetrahydrofuran                                                        .sup.11 Dimethylformamide                                                      .sup.12 Sold by Firestone Fire & Rubber Company                                .sup.13 Sold by B. F. Goodrich Company                                         .sup.14 Polyvinyl acetate                                                      .sup.15 Hydroxyl                                                               .sup.16 Methyl isobutyl ketone                                                 .sup.17 Sold by Armstrong World Industries, Inc.                               .sup.18 Sold by Whittaker Corp.                                                .sup.19 Sold by Ciba Geigy Corporation                                         .sup.20 Sold by Mobay Chemical Corp.                                           .sup.21 Trimethyl hexamethylene diisocyanate                                   .sup.22 Sold by Congoleum Corp.                                                .sup.23 Sold by Del Val Ink & Color Inc.                                       .sup.24 Isopropyl acetate                                                      .sup.25 Sold by Hechinger Co.                                                  .sup.26 Sold by Textron Inc.                                                   .sup.27 Paratoluenesulfonic acid                                               .sup.28 Sold by Seton Leather Company                                          .sup.29 Sold by AerojetGeneral Corporation                                     .sup.30 Butyl cellosolve acetate sold by Union Carbide Corp.                   .sup.31 Sold by Dow Chemical Company                                           .sup.32 Sold by Shawinigan Products Corporation                                .sup.33 Sold by Carwin Company                                                 .sup.34 Sold by General Mills, Inc.                                            .sup.35 Sold by Shell Chemical Corporation                                     .sup.36 A melamine low temperature crosslinker                                 .sup.37 Sold by Ashland Oil, Inc.                                              .sup.38 Sold by Spencer Kellogg                                          

Cyanoacrylate monomers were the only resinous system that showed adequate adhesion to the wear layer. Table 3 lists the cyanoacrylates and amine accelerators which were evaluated.

                  TABLE 3                                                          ______________________________________                                         Cyanoacrylates Monomers                                                                                      Viscosity                                        Designation     Cyanoacrylate Ester                                                                          (CPS)                                            ______________________________________                                         Loctite ® 401.sup.1                                                                        Ethyl         100                                              Loctite ® 403                                                                              Methoxy ethyl 1,000                                            Loctite ® 411                                                                              Modified ethyl                                                                               5,000                                            Loctite ® 414                                                                              Ethyl         120                                              Loctite ® 430                                                                              Methyl         80                                              Loctite ® 447                                                                              Ethyl         600                                              Loctite ® 460                                                                              Methoxy ethyl  50                                              Permabond ® 102.sup.2                                                                      Ethyl         100                                              Permabond ® 130                                                                            Methyl        500                                              Permabond ® 910                                                                            Methyl        100                                              Permabond ® 5238-143A                                                                      Ethyl + 5% DMP.sup.3                                                                         --                                               Permabond ® 5238-143B                                                                      Ethyl + 10% DMP                                                                              --                                               Hernon's Instantbond 105.sup.4                                                                 Methyl        1-5                                              Hernon's Instantbond 110                                                                       Methyl        100                                              Hernon's Instantbond 117                                                                       Ethyl         1,300-1,700                                      Hernon's Instantbond 123                                                                       Ethyl         100-120                                          Hernon's Instantbond 126                                                                       "Rubber" modified                                                                            2,000                                            Hernon's Instantbond 127                                                                       "Rubber" modified                                                                            4,000-6,000                                      ______________________________________                                         Cyanoacrylate Accelerators and Primers                                                    % Active                                                            Designation                                                                               Ingredient                                                                               Composition  Solvent                                      ______________________________________                                         Loctite    1.0       Sulfenamide.sup.5                                                                           1,1,1-tri-                                   Activator 711                     chloroethane                                 Loctite    0.1         "          1,1,1,-tri-                                  Activator 702                     chloroethane                                 Loctite     0.1        "          1,1,1,-tri-                                  Activator 703                     chloroethane                                 Loctite    1.0       Modified     Freon 113/                                   Activator            sulfenamide  acetone 85/15                                FMD-146                                                                        Permabond  1.0       DMPT.sup.6   1,1,1-tri-                                   Q.F.S.                            chloroethane                                 Permabond 27A                                                                             1.0       Modified DMPT                                                                               1,1,1-tri-                                                                     chloroethane                                 Permabond 27B                                                                             1.0       Phenyl ethyl 1,1,1-tri-                                                        ethanolamine chloroethane                                 Hernon Primer 20                                                                          1.0       DMPT         trichloro                                                                      trifluoro                                                                      ethane                                       Hernon Primer 22                                                                          0.5       DMPT         trichloro                                                                      trifluoro                                                                      ethane                                       ______________________________________                                          .sup.1 Sold by Loctite Corporation                                             .sup.2 Sold by National Starch and Chemical Corp.                              .sup.3 Dimethyl phthalate                                                      .sup.4 Sold by Hernon Mfg. Inc.                                                .sup.5 Sold by Vanderbilt Chemical Corp. under the registered trademark        Amax                                                                           .sup.6 Dimethyl ptoluidine                                               

For the adhesion evaluations, the cyanoacrylates were applied to floor coverings having the aminoplast/polyol wear layer, optionally leveled with an applicator tip and sprayed with various amine accelerators using a hand-operated atomizer. The accelerator was applied ten minutes after the coating composition was applied. Ethyl esters which had a viscosity of approximately 100 CPS were the most promising.

Physical properties of samples prepared at ambient conditions of 75° F. and 34% relative humidity were evaluated. The results are shown in Table 4.

                                      TABLE 4                                      __________________________________________________________________________              Accelerator                                                                    or Primer                Ultra-Violet                                          (% active      Household.sup.1 Stain                                                                    Discoloration Test                           Cyanoacrylate                                                                            ingredient)                                                                            Adhesion                                                                             Resistance - 3 Hours                                                                     3 days                                                                              5 days                                  __________________________________________________________________________     Loctite 401                                                                             711 (1.0%)                                                                              Chipped off                                                                          000040    mod.sup.2                                                                           mod                                                       w/difficulty                                                 "        702 (.1%)                                                                               Good  000020    v.sl.sup.3                                                                          v.sl                                    "        703 (0.01%)                                                                             Good  000020    v.sl v.sl                                    "        FMD-146  Good  000000    none none                                             (experimental)                                                        Permabond 102                                                                           Q.F.S. (1%)                                                                             Poor  010040    severe                                                                              severe                                  "        27A (1%) Poor  000040    none none                                    "        27B (1%) Poor  020240    mod  mod                                     Permabond 143A                                                                          Q.F.S. (1%)                                                                             Poor  010240    severe                                                                              severe                                  "        27A (1%) Poor  010340    none none                                    "        27B (1%) Poor  000340    mod  mod                                     Hernon 123                                                                              Primer 20 (1%)                                                                          Poor  000030    none none                                    "        Primer 22 (0.5%)                                                                        Poor  000030    none none                                    Loctite 401                                                                             None     Good  000010    v.sl v.sl                                    Permabond 102                                                                           None     Good  000030    none none                                    Hernon 123                                                                              None     Good  000040    none none                                    __________________________________________________________________________      .sup.1 Ball Point Pen Ink, Magic Marker, Brown Shoe Polish, Hair Dye,          Iodine 3% and Driveway Sealer, respectively. A higher number indicates         darker stain.                                                                   .sup.2 Moderate                                                               .sup.3 Very slight                                                       

The use of higher concentration accelerators resulted in poor adhesion because the speed of cure was too fast to allow the monomers to wet-out or penetrate the wear layer surface. If the accelerators were applied to the wear layer surface before the cyanoacrylates, the adhesion was poorer for the same reason. Most of the cyanoacrylates showed good household stain resistance in three hour tests except for iodine. The more severe discoloration generally occurred with the higher concentrations of accelerator.

Further physical property tests were run at 75° F. and 66% relative humidity. The results of these tests are set forth in Tables 5 and 6.

                  TABLE 5                                                          ______________________________________                                                                               Adhesion                                                                       180° flex                                   Accelerator         Surface 2 days                                   Cyanoacrylate                                                                            or Primer  Frosting Texture old                                      ______________________________________                                         Loctite 401                                                                              702 (0.1%) v. slight                                                                               good gloss                                                                             good                                                                   v. slight                                                                      shrivel                                          Loctite 460                                                                              702 (0.1%) v. slight                                                                               good gloss                                                                             good                                                                   v. slight                                                                      shrivel                                          Loctite 430                                                                              702 (0.1%) v. slight                                                                               good gloss                                                                             good                                                                   v. slight                                                                      shrivel                                          Permabond 102                                                                            Q.F.S. (1%)                                                                               slight   sl. grainy                                                                             poor                                     Permabond Q.F.S. (1%)                                                                               slight   gnarled poor                                     143A                                                                           Permabond Q.F.S. (1%)                                                                               slight   sl. grainy                                                                             good                                     143B                                                                           Instantbond 123                                                                          Primer 20  v. sl    good gloss                                                                             poor                                               (1%)                                                                 Instantbond 110                                                                          Primer 20  v. sl    severe  good                                               (1%)                whitening                                        ______________________________________                                    

                  TABLE 6                                                          ______________________________________                                                                             Adhesion                                             Accelerator General Comments                                                                             Four                                       Cyanoacrylate                                                                            or Primer   One Day       Days                                       ______________________________________                                         Loctite 460                                                                              702 (0.1%)  iodine resistance                                                                            good                                       (methoxy ethyl)       poor, grainy surface                                     Loctite 430                                                                              702 (0.1%)  good overall  good                                       (methyl)                                                                       Loctite 401                                                                              702 (0.1%)  sl. grainy, good                                                                             good                                       (ethyl)               gloss and iodine                                                               resistance                                               Permabond 102                                                                            Q.F.S. (1%) good iodine   poor                                       (ethyl)               resistance    (pops off)                                 Permabond Q.F.S. (1%) iodine worse than                                                                            good                                       5238-143A             Permabond 102                                            Permabond Q.F.S. (1%) iodine worse than                                                                            poor                                       5238-143B             Permabond     (pops off)                                                       5238-143A                                                Instantbond 123                                                                          Primer 20 (1%)                                                                             low frosting, poor                                       (ethyl)               no shrivel,   (pops off)                                                       iodine OK,                                                                     adhesion good                                            Instantbond 100                                                                          Primer 20 (1%)                                                                             grainy, no    good, but                                  (methyl)              frosting      brittle                                                                        when                                                                           rubbed                                     ______________________________________                                    

Again, at lower accelerator concentrations, the cyanoacrylates exhibited good adhesion.

The cyanoacrylate monomers are very volatile and their vapors can escape from the seam coater bead before curing starts and redeposit alongside of it causing a white "frosted" appearance (chlorsis). To combat this, the surface may be sprayed with a very low solids amine accelerator in trichloroethane or Freon solvents. If the concentration or coverage is too low, "frosting" occurs. If the concentration or coverage is too high, the cure is too rapid leading to distorted gnarled surface textures. If no accelerator is used the surface cures with a dull grainy surface depending on the relative humidity. The "frosting" and the cured cyanoacrylates can be removed from wear layer surface with nitroethane.

Floor coverings were installed with an epoxy adhesive under the seams. In coating with seams with cyanoacrylates, the polyamide hardening agent in the epoxy adhesive remaining on the surface and/or its vapors were present. This caused the cyanoacrylate to cure prematurely resulting in poor adhesion and a whitening in the coating itself. When installed with an aqueous adhesive, the problem did not occur.

Stain resistance was determined on two of the polyurethane coatings (Desmodur W and Desmodur W3398), Loctite 401 and the wear layer without a seam coating. The results are set forth in Table 7.

                                      TABLE 7                                      __________________________________________________________________________              Asphalt                                                                               Antioxidant                                                                            Household                                                                              Stain                                          Seam Coater                                                                             Tracking                                                                              Staining                                                                               Staining                                                                               Resistance                                     __________________________________________________________________________     Desmodur W                                                                              12.4 + 4.3   + 18.8  = 35.5                                           Desmodur W3398                                                                          7.5  + 4.7   + 11.7  = 23.9                                           Loctite 401                                                                             5.7  + 4.5   +  3.7  = 13.9                                           Wear Layer                                                                              6.7  + 6.8   +  1.6  = 15.1                                           __________________________________________________________________________      (A lower number indicates less staining).                                

The two polyurethane coatings were significantly less stain resistant than either the cyanoacrylate monomer coating or the wear layer itself. The cyanoacrylate monomer coating was similar to the wear layer.

As stated previously, 2-ethyl cyanoacrylate is the preferred monomer for use with the aminoplast/polyol wear layer. If the cyanoacrylate is modified by the addition of a phthalic acid ester, and particularly dibutyl phthalate, the cyanoacrylate may be applied to the seam by brush. Further, the phthalic acid ester modified cyanoacrylate more closely matches the wear appearance properties of the aminoplast/polyol wear layer. The dibutyl phthalate modified 2-ethyl cyanoacrylate is sold by National Starch and Chemical Corporation under the designation Permabond BK#5235-149A. 

What is claimed is:
 1. A method of seam coating a surface covering product having an exposed surface comprising the reaction product of a protective coating composition including an aminoplast and a polyol, the method comprising applying to the seam of the surface covering a seam coating composition comprising cyanoacrylate monomer.
 2. The method of claim 1 wherein the cyanoacrylate monomer is selected from the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate, propyl 2-cyanoacrylate, butyl 2-cyanoacrylate, methoxy ethyl 2-cyanoacrylate, methoxy methyl 2-cyanoacrylate, ethoxy methyl 2-cyanoacrylate and ethoxy ethyl 2-cyanoacrylate.
 3. The method of claim 2 wherein the cyanoacrylate monomer is selected from the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate and methoxy ethyl 2-cyanoacrylate.
 4. The method of claim 1 wherein the seam coating composition comprises at least two cyanoacrylate monomers.
 5. The method of claim 1 wherein the seam coating composition further comprises a plasticizer.
 6. The method of claim 5 wherein the plasticizer is a phthalic acid ester.
 7. The method of claim 6 wherein the phthalic acid ester is about two percent to about thirty percent by weight of the seam coating composition.
 8. The method of claim 6 wherein the phthalic acid ester is the esterification product of phthalic acid and an organic group selected from the group consisting of an alkanol comprising two to ten carbon atoms, benzyl alcohol, benzyl alcohol derivatives and mixtures thereof.
 9. The method of claim 8 wherein the phthalic acid ester is selected from the group consisting of dibutyl phthalate, dihexyl phthalate, dioctyl phthalate and butyl benzyl phthalate.
 10. The method of claim 9 wherein the phthalic acid ester is dibutyl phthalate.
 11. The method of claim 1 wherein the seam coating composition is clear after it is cured.
 12. The method of claim 1 further comprising applying in accelerator to the uncured seam coating composition.
 13. The method of claim 12 wherein the accelerator is an amine.
 14. The method of claim 13 wherein the amine is sulfenamide, phenyl(C₁ -C₆)alkyl(C₁ -C₆)alkanol amine or (C₁ -C₈)alkyl-substituted p-toluidine.
 15. The method of claim 14 wherein the amine is selected from the group consisting of N-oxydiethylene benzothiazol-2-sulfenamide, phenyl ethyl ethanol amine and dimethyl p-toluidine.
 16. The method of claim 1 wherein the aminoplast is a melamine.
 17. The method of claim 16 wherein the melamine is alkyl etherified with alkyl groups comprising 1 to 10 carbon atoms.
 18. The method of claim 17 wherein the alkyl groups have 1 to 4 carbon atoms.
 19. The method of claim 1 wherein the protective coating composition further comprises a vinyl resin.
 20. The method of claim 19 wherein the vinyl resin is selected from the group consisting of VAGH, VAGD, VROH and VYES.
 21. The method of claim 1 wherein the seam coating is brushable after application on the seam and prior to being cured.
 22. The method of claim 1 wherein the seam coating has a viscosity of about 50 to about 300 CPS at the time of application.
 23. The method of claim 22 wherein the seam coating has a viscosity of about 100 CPS at the time of application.
 24. A flooring system comprising two floor coverings each having an exposed surface comprising the reaction product of a protective coating composition including an aminoplast and a polyol, said floor coverings having abutting edges forming a seam, and a seam coating applied to the seam comprising cyanoacrylate monomer.
 25. The flooring system of claim 24 wherein the cyanoacrylate monomer is selected from the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate, propyl 2-cyanoacrylate, butyl 2-cyanoacrylate, methoxy ethyl 2-cyanoacrylate, methoxy methyl 2-cyanoacrylate, ethoxy methyl 2-cyanoacrylate and ethoxy ethyl 2-cyanoacrylate.
 26. The flooring system of claim 24 wherein the seam coating further comprises a plasticizer.
 27. The flooring system of claim 24 wherein the aminoplast is a melamine.
 28. The flooring system of claim 27 wherein the melamine is alkyl etherified with alkyl groups comprising 2 to 10 carbon atoms.
 29. The flooring system of claim 24 wherein the protective coating composition further comprises a vinyl resin. 